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HydroLink2 Supervisory Control PanelApplication and Troubleshooting Guide

For use in all equipment utilizing the HydroLink2 Aurora Control

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HYDROLINK2 AURORA SUPERVISORY CONTROL PANEL APPLICATION GUIDE

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

HydroLink2 Aurora Supervisory Control Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Staging Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

HSC Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Mounting Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

HSC Wiring Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Field Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

HMI Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

HMI Screens Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Change HSC Network IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Powering on HMI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Login Screen (Pre Factory Tech Startup) First Time Connecting. . . . . . . . . . . . . . . . . . . . . . .33

Application Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Four Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller . . . . . . . . . .34

Four Pipe Reversing Header Rack with Fixed Capacity Scroll Dedicated Chiller . . . . . . . . 40

Four Pipe Standard Header Rack with Fixed Capacity Scroll Reversible Chiller . . . . . . . . . .46

Six Pipe Dedicated Header Rack with Reversible Chiller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Six Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller . . . . . . . . . . .58

HydroLink2 Aurora Control Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64

HMI Reloading/Rebooting Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

BACnet Pointslists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Port Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Revision Guide. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

4


The HydroLink 2 Supervisory Control Panel is a Niagara AX based control, designed to automate the chiller assembly with

an application specific supervisory control. By using an application specific control, optimal plant room management can

be obtained to insure proper operation and easier servicing with a turnkey solution. It features a Niagara AX based control

with its own I/O and a color touchscreen tablet as a user interface. Turn-key custom programming of the Supervisory

Control will be provided based upon your specific requirements for the whole chiller plant to manage the chillers and as an

option, the pumps and other hydronic specialties.

Benefits of the HydroLink2 Supervisory control:

• It is a powerful and flexible Niagara AX software platform based controller.

• Optimal supervisory control programming to meet your specific site specifications.

• Customized integration of mechanical room components such as variable speed pumps and other hydronic specialties

of the plant room into the site BAS.

• Guaranteed compatibility of the Supervisory Controller with the Unit Controllers.

• The sophistication of the Niagara based control allows better equipment support and servicing. Customer benefits

from our experience in providing custom Supervisory Controllers.

• Improved system visibility from the BAS.

The HSC Panel is the ideal match to manage your complete chiller mechanical room.

Introduction

HydroLink2 Supervisory ControlHyHydrdroLoLinink2k2 Supervisory Control

5


HydroLink2 Supervisory Control Features• HydroLink 2 Control uses the powerful NIAGARA

software platform.

• Internal power supply and a 120Vac convenience outlet

are built into the cabinet.

• Over 2 sq. ft. [0.19 m2 of control mounting area for

custom controls such as relays or transducers.

• Provides for a customized programmed chiller plant

controller.

• Internal mounted and wired 10” Touch Screen tablet for

interfacing with Supervisory Controller. HydroLink2 Supervisory Controller

utlet

nt

et for HydroLink2 Supervisory Controller

115Vac to 24 Vac Transformer

Optional 115Vac Power

Outlet

6


HydroLink2 Supervisory Control Features cont.

BACnet MS/TP Network

• Niagara AX Based.

• Supports BACnet MS/TP, BACnet IP, and LonWorks® as standard BAS options

• Can stage up to five screw compressors or ten scroll compressors

• Run time equalization supported

• Compressor fault compensation staging logic

• Unit overide detection and compensation staging logic

• Manual compressor lockout recognition logic to allow unit servicing without disrupting the staging continuity

• Supports heating-only, cooling-only, and simultaneous heating and cooling

• Customizeable I/O local to the supervisory controller to support peripheral mechanical room devices such as pumps,

valves, cooling towers, and flow monitoring equipment

• Local Display with touch screen control to navigate through screens showing operational data

• Network variables to allow direct BAS control and monitoring of unused IO on the IO34

• Historical trending of key temperatures and statuses

7


HydroLink2 Supervisory Control Features cont.

The HydroLink Supervisory Control (HSC) is scazlable from two to five dual scroll Reversible Chillers or two to five single

screw compressor chillers. Heating and cooling mode are both supported. The control algorithm is a PID based algorithm

that operates a sequencing logic which determines which chiller is next in the sequence based on unit run time, local

overrides, BAS overrides, as well as unit fault status.

The PID compares the controlled water temperature to the desired temperature (Set Point) and the controlled water

temperature of the previous few minutes in order to generate a demand percentage for capacity. The sequencing logic will

respond to capacity demand changes by starting or stopping a compressor to a chiller. If the demand is increasing and

crosses a threshold for starting another compressor, the sequencing logic will do one of two things: If a chiller is running

only one compressor, the second compressor will be started. Otherwise, the logic will select a non-running and non-faulted

chiller with the least amount of run time and issue a compressor command to that chiller. If the demand is decreasing and

crosses a threshold for stopping a compressor, the sequencing logic will do one of two things: If a chiller is running only one

compressor, that compressor will be stopped. Otherwise, the logic will select from the running chillers the chiller with the

highest run time and remove one of the compressor calls.

The supervisory controller can be programmed for communications to virtually any type of BAS. BACnet is the standard

option for the supervisor’s BAS connection. Peripheral devices such as pumps and other chiller plant equipment can—on a

custom basis—be added to the control of the supervisor. Contact the manufacturer for more info.

8


Staging Description

OverviewThe HydroLink 2 Supervisory Control (HSC), has staging software that can be enabled or disabled by a single binary (two-

state) variable named “SystemEnable.” The mode of operation is selected by a multi-state variable called “SystemMode”

which indicates to the program which setpoints (heating or cooling) and mode of operation will be used. The HSC selected

mode is communicated to each individual unit controller. If the system configuration includes a six-pipe header rack,

then the capabilities of simultaneous heating and cooling will be functional. If a simultaneous mode is selected, the unit

controllers will modulate the three-way water valves on the header rack to blend the source fluid with the “secondary load”

fluid to maintain a temperature setpoint while the HSC will stage on and off the individual compressors to maintain the

“primary load” fluid temperature. If the piping configuration is not a six-pipe, then simultaneous heating and cooling modes

will not function. In the heating-only or cooling-only modes, the HSC will stage compressors on or off to maintain the

desired header rack leaving water temperature.

Fixed Speed Scroll CompressorsThe HSC will stage units based on:

• Leaving water temperature

• Compressor fault status

• Unit run time

The staging logic uses a specialized PID control algorithm that is designed to control stepped capacity systems. The

control algorithm not only has the standard proportional and integral features, but also a derivative feature that is used to

recognize short and long term load responses to capacity changes and to ambient temperature influences. This feature

improves the capacity-to-load matching accuracy and is predictive. The output range of the PID control is 0% to 100%. This

range is divided into equal segments to provide turn-on and turn-off thresholds for the compressors. If the option selected

were a 4 compressor stager, then the first compressor would be turned on when the PID output reaches 25%. The second

at 50%, the third at 75% and the fourth at 100%. For staging down, the first ‘stop’ command would be issued at 75%, the

second at 50%, the third at 25%, and the fourth at 0% output of the PID. When a start or a stop command is issued, a

delay timer is initiated. While the delay timer is active, the PID is ‘frozen’ at the current value so that the system capacity

change can begin to take effect. When the timer has expired, the derivative portion of the PID will be able to freeze the

PID output if the water temperature is moving toward the setpoint at a satisfactory rate—staging up or down. This will

reduce the likelihood of engaging or dropping too many stages and causing severe overshoot of setpoint. When staging

up, the staging logic will select the next unit based on unit cumulative run time. If there’s a unit with only one compressor

commanded on, then the second compressor in that unit will be the next one to be turned on. Otherwise, the staging logic

will issue a compressor call to the non-running unit that has the least amount of runtime and shows no compressor faults

or lock-outs. Likewise, when staging down, if there’s a unit with only one compressor running, that compressor will be the

next one off. Otherwise, the staging logic will remove a compressor call from the running unit with the most run time. The

staging logic recognizes a manually locked-out compressor and will remove it from the staging sequence to avoid ‘dead

spots’ in the staging response. An adjustable deadband is used to reduce the on/off cycling of compressors when the

controlled water temperature is reasonably close to the set point.

9


Mounting Details

Mount HSC Panel indoors and within close proximity to the mechanical room that houses the chillers and devices it

controls. The HSC Panel must be free and clear of any obstructions that prevent access to and within the enclosure. The

HSC Panel can attach to a wall or to an optional stand capable of supporting the HSC Panel. Installation shall meet or

exceed all local building codes.

The back of the HSC Panel has keyways at the top and bottom of the panel at 16 inches on center to provide easy mounting

points.

HSC Installation Requirements

Mounted HSC Panel Indoors

• Location must be free of moisture and excessive heat and dust.

• Ambient conditions should not exceed 35°F to 110°F (0 to 90% RH, non-condensing).

• Location must allow HSC Panel door to swing open free of obstruction.

• Mounting and wiring must meet or exceed all local building codes.

• Dedicated 115/120V power supply

16.0 2.4

2.1

24.0

4.0

2.0

4.0

2.0

4.0 4.0

3.3 (2)

20.6

28.5

3.3 (4)

0.38 x 0.75 x 1.25KEYWAY

3.3 (3)

2.45.55.5

LOCKTOUCHPAD DISPLAY COLOR SCREEN

3.3

4.0

2.0

4.0

2.0

DOOR LATCHES

**ALL DIMENSIONED HOLES ARE KNOCK OUTS

7/8" AND 1 3/8" IN SIZE

6.6

10


Supervisory Control Box Electrical RequirementsBreaker Size: 20A

Wire Size: 14AWG

NOTE: Dedicated 115V/120V Power Supply Required

Min Supply Voltage: 105V

Max Supply Voltage: 127V

11


HSC Wiring Requirements

Field Wiring

All EIA-485 communication wiring connections shall be made with communication wire that meets or exceeds the

specifications shown in ANSI/ASHRAE Standard 135.

• Installing contractor will complete the wiring of the HSC.

• BACnet I/P – A communication protocol that should only be used to connect the HydroLink 2 Supervisory

Controller to the Building Automation System if so desired.

• BACnet MS/TP – A communication protocol that is used to connect the HSC Panel to the unit mounted Hy-

droLink 2 controllers, and can be used by the Building Automation System on the “RS-485 option card.

• Daisy Chain – A wiring method used when connecting RS-485 MS/TP communication protocol. This method

should be used to connect the HSC Panel to the unit mounted HydroLink 2 controllers.

The HSC Panel requires a dedicated 120VAC be fi eld wired for power. The HydroLink2 controller will be factory wired in the

panel to a dedicated 24VDC circuit. The BAS communications, the local chiller communications trunk, the header rack isola-

tion valves, header rack pressure transducer and header rack temperature sensors are to be wired in the fi eld by the install-

ing contractor. If the BAS connection is BACnet MS/TP, the recommended cable is a 22 AWG stranded shielded twisted pair.

The local chiller communications trunk is also recommended to be a 22 AWG stranded shielded twisted pair.

The HMI (Human Machine Interface) is also factory pre-wired for power and communication to the supervisory controller.

The HMI will connect to the HydroLink 2 Supervisory Controller via Lan 2, this will allow the tablet to display the screens

used for setup and confi guration. Refer to the “HMI reloading/rebooting Procedure” section or contact the WFI tech sup-

port team for questions or assistance with the HMI application.

• 24VDC power supply is dedicated to power the HydroLink2, Onyxx XM 34IO and Onyxx XM 34IO-B devices. DO NOT

connect other equipment to this dedicated power supply.

• Do not apply 24VAC power by reinserting the connector plug into the HydroLink2, Onyxx XM 34IO or Onyxx 34IO-B)

until all other wiring is completed, including the Onyxx XM 34IO, or Onyxx XM 34IO-B inputs and outputs. Screw down

all connector screws prior to testing & installation.

12


HMI Screens

Log-In ScreenOnce the configuration setup is complete, there will be a “HydroLink Aurora logo” in the center of the screen. The “System”

button on the navigation bar will become enabled, and display the module count for the system. For example, “System 2U

stands for “System with (2) Units.” (See picture below).

NOTE: All other links on the navigation bar are disabled on the “Login” screen. Click on the “System” button, (example

shows “System 2U”) then the entire navigation bar will be enabled, and the HMI will display the “System” screen. Once end-

user leaves the “login” screen, navigate each screen in the HSC, and verify that the data on the Units HMI is matching the

data on the Supervisory HMI.

13


HMI Screens

System ScreenDisplays chiller Enabled/Disabled Status, System Entering/Leaving Fluid Temperatures, System Mode, and the System

Setpoints will appear on the “System” screen.

System Setpoints: – Displays the Heating and Cooling setpoints, which the program uses to control capacity to operate the

system and is adjustable from the Temperature Control screen on Settings screen.

System Mode: Displays the current operating mode selected of the system, and is adjustable from the Temperature Control

screen on Settings screen.

Hot / Cold / Net Energy Fluid:• Leaving (°F) – This is the Header Rack leaving fluid temperature, that can be shown in °F or °C.

• Entering (°F) – This is the Header Rack entering fluid temperature, that can be shown in °F or °C.

Chiller Status: Displays the current command of the unit such as “Enabled” or “Disabled.”

Navigation Tool Bar All HSC screens on the HMI will display a navigation tool bar at the top of the screen, which includes the following links:

“Header Rack,” “System,” “Overview,” and a “Settings” link that will allow the end user to view more details about the

system.

NOTE: The number of modules in the system will appear on the System and Overview buttons in the navigation bar. (See

screenshot below)

Note: Example shown has a 6 pipe header rack.

14


HMI Screens cont.

Header Rack Screen Displays header rack entering/leaving fluid temperatures, differential pressures (if available), bypass valve, three-way

valve, and isolation valve position. Also shown on this screen, “heating and cooling” set points, control temperature, mode

selected, and “Active Alert Status.

Header: Displays the current selected header rack type of the system, and is adjustable from the Temperature Control


Header Mode: Displays the current operating mode selected of the system, and is adjustable from the Temperature Control


Header Rack Valves: Displays the current command of each valve on the header rack.

• Bypass (0-100%)

-Hot/Cold/Net Energy bypass valves will modulate to provide the constant flow thru the header rack as chillers

start to enable/disable to control capacity.

• 3Way (0-100%)

-Load/Source 3way valves will modulate to blend fluid to control the hot and cold loops in the simultaneous heat/

cool modes (NOTE: These modes only work with a 6-pipe header rack configuration).

• Isolation (Off/On)

-Load/Source Isolation valves are to open (On) and close (Off) as the staging software enables and disables the

chiller.

Active Alert Status: • System Maintenance (Normal / Alarm) - Provides an alarm that will trigger every 90-calendar days, to remind owner to

check and clean strainers. This requires a hard reset from the HMI.

• Temp Sensor Failure (Normal / Alarm) – Provides an alarm if any header rack temperature sensor becomes out of range

or offline. (True(Alarm) if sensor out of range and False(Normal) if sensors are within range)

• High Header Temp (Normal / Alarm) - Will monitor the entering header fluid temperature. True (Alarm) if sensor out of

range and temp is too HIGH, and a False (Normal) if sensors are within range).

• Low Header Temp (Normal / Alarm) -Will monitor the entering header fluid temperature. True (Alarm) if sensor out of

range and temp is too LOW, and a False (Normal)

15


HMI Screens cont.

Header Rack Screens cont. .If the “No Header Rack” option is selected for the Header Rack Type, when the Header Rack screen is activated a display

indicating the system is not configured for a header rack will be displayed.

16


HMI Screens cont.

Overview Screen Displays chiller status, operation, compressor lockout status, heating and cooling set points, and compressor contactor

status. This screen gives an overview of each chiller.

Setpoint – (Heating / Cooling) the selected setpoint the unit is trying to maintain.

Control Temp – The current temperature of the control sensor.

Status: Displays the current overall fault status of chiller. “Normal” for normal operation or “Lockout” indicating the unit has

locked out due to a fault.

Operation: Displays the current operating condition of unit such as “Standby” or “Single Compressor Cooling.”

Mode: Displays the current operating mode selected of the chiller, and is adjustable from the Manual Operation screen on

Settings screen.

Circuit A & B: Displays the On/Off status, and the current lockout status of each compressor detected by Aurora Boards.

17


HMI Screens cont.

Settings Screen All temperature, network, or capacity settings for the system or HydroLink controller can be accessed or changed thru the

“Settings” screen. The method of temperature control, mode of operation, and manual operation all take place in this

screen.

18


HMI Screens cont.Header Rack Settings ScreenAllows the end-user to configure the header rack functionality.

Header Graphic Type – Displays the existing header rack type and provides the appropriate header information for that

header rack type.

Header Logic Type – Displays the existing header rack type and provides the appropriate header logic for that header rack

type.

Header System Control - Selection between Setpoint (False) and Aqua Stat (True) control for some header rack.

Differential Pressure Enable – Displays the current header rack DP across the header Rack’s entering/leaving fluid.

System Control Temp Option – Displays the controlled variable that the system uses to control capacity. (Header Rack

LWT/Storage Tank Temp) -

Full Building (Auto) Control Temp – Used in FBA mode ONLY, displays the controlled variable that controls the secondary

loop leaving water temperature. (Header Rack LWT/Heat Exchanger LWT) -

19


HMI Screens cont.Temperature Control Settings Screen Allows user to adjust the heating and cooling setpoints, and the setpoint reset (from the BAS). The effective setpoint of the

system are also displayed.

Temperature Control Method – Displays the control method current selection to operate the system. The three options

include:

• Setpoint Control – Manual Control; will use selectable onboard sensors at the unit level and control via a PID loop.

• Aqua Stat Control - Using external (field supplied) temperature sensor and 24VAC commands directly to the unit.

• Network Control – Supervisor Control; Operation commands will come directly thru Supervisory Controller (BACnet

MS/TP) communication or from the BAS.

Heating Settings Hot Setpoint: Heating set point used for system capacity control in heating modes.

Hot Setpoint Reset: Allows a reset value command ranging from {+/- 5 degrees} to reset the system hot-water set point.

Hot Effective Setpoint: A combination of the Hot Set point, and the Hot Setpoint Reset, used for system capacity control in

heating modes.

Cooling Settings

Cold Setpoint: Cooling set point used for system capacity control in cooling modes.

Cold Setpoint Reset: Allows a reset value command ranging from {+/- 5 degrees} to reset the system cold-water set point.

Cold Effective Setpoint: A combination of the Cold Setpoint, and the Cold Setpoint Reset, used for system capacity control

in cooling modes.

20


HMI Screens cont.Unit Manual Operation ScreenDisplays the system-level manual commands and some statuses. It also displays the current unit operating status with links

to the unit-level manual commands.

System Enable: Allows units to run using the “Auto Staging Program” this should be enabled at all the times for units to

operate using the staging program. If disabled, the units are commanded off from the Supervisory controller.

System Mode: Allows the user to change modes on the system.

Integrated Hydrolink Aurora Controls have 8 operating modes (shown below) to select from:

1 – Compressors Off, Isolation Valves Open

2 – Cooling Only

3 – Heating Only

4 – Auto Full Building - (6-pipe header)

5 – Full Building

6 – Primary Cooling - (6-pipe header)

7 – Primary Heating - (6-pipe header)

8 – System Off - (Compressors off, Isolation Valves Closed)

Emergency Shutdown: Enable (On) or Disable (Off) Emergency Shutdown. This command will immediately (5 sec)

shutdown all compressor and any other outputs. This screen shows whether it is active or not.

Capacity Limit Enable: This variable should be set to “On” (True) to enable the limiting functionality, and set to “Off” (False)

to disable this feature. The default set to Off.

Capacity Limit Setting: The system will be limited to the capacity limit setting. This parameter displays the number of units

that is available to operate in the system, and is used to limit energy consumption during peak hours. The default setting is

setup to operate at 100%.

NOTE: See the example of systems and the ability to limit the capacity in the table below.

Unit Manual Ops: Allows access to a unit-level manual operations screen, which allows some override commands to an

individual unit.

21


HMI Screens cont.

Unit Manual Operation Screen cont.Displays the unit-level manual commands and some active statuses. Allows the user to override some commands for

individual unit control.

Unit Manual Control Option

Emergency Shutdown: Will immediately (5 sec) shutdown all compressors and any other outputs. This screen shows

whether it is in shutdown or a normal state.

Reset Alarms:

• Reset - Allows program to reset the alarms.

• Normal - Allows program to operate as normal with no alarms.

Enable Override: If set to overridden, user will take unit out of the “Auto Staging Program” rotation and enable/disable unit

manually.

Mode Override: Must be set to “Auto” for HSC to stage. If “Not set to AUTO” user will take unit out of the “Auto Staging

Program” rotation and can pick a different mode for that unit.

Unit Control Program Option

Network Control: • Network - Indicates that the system is under Supervisory (HSC) control.

• Normal - Indicates the unit will operate as a stand-alone unit.

Temperature Control Method – Displays the control method current selection to operate the system. The three options

include,

• Setpoint Control – Manual Control; will use selectable onboard sensors at the unit level and control via a PID loop.

• Aqua stat Control - Using external (field supplied) temperature sensor and 24VAC commands directly to the unit.

• Network Control – Supervisor Control; Operation commands will come directly thru Supervisory Controller (BACnet

Mstp) communication.

Unit Active StatusThese values are indicating the unit’s current operating status.

NOTE: When the “Mode Override and/or Enable Override” feature is activated, the unit is taken out of the “Auto Staging

Program” sequence and will only operate manually via the Local- HMI at the chiller.

22


HMI Screens cont.

Capacity SettingsDisplays the staging values and parameters for increasing/decreasing capacity control for the system.

Unit Stage On Settings

Capacity Setpoint: (Adjustable) Refers to unit capacity setpoint.

This value is 1/3 part of the “stage on” criteria.

When the average capacity setpoint (Enabled Units) is greater than this value, the “stage on timer” will start.

Hot Delta: (Adjustable) Hot water stage on differential.

This value is 2/3 part of the “stage on” criteria (Applies when in Heating modes).

When the hot header leaving water temperature is less than the hot water set point, by the difference of this value, then the

“stage on timer” will start.

Cold Delta: (Adjustable) Chilled water stage on differential.

This value is 2/3 part of the “stage on” criteria (Applies when in Cooling modes).

When the cold header leaving water temperature is greater than the cold-water set point, by the difference of this value,

then the “stage on timer” will start.

Timer Setpoint: (Adjustable) This value is 3/3 part of the “stage on” criteria.

This timer will start when the enabled units, meet the criteria to stage on is met. When timer expires, and the stage on

criteria is satisfied, the next unit will be enabled with the least amount of runtime by the HSC.

Time Remaining: (Non-Adjustable) This value is 3/3 part of the “stage on” criteria.

The remaining time left of the “stage on timer” to enable the unit with the least amount of runtime..

23


Capacity Settings cont..

Unit Stage Off Settings

Capacity Setpoint: (Non-Adjustable) Refers to unit capacity setpoint.

This value is (1/3) part of the “stage off” criteria.

When the average capacity setpoint (Enabled Units) is less than this value the “stage off timer” will start.

Cold Delta: (Adjustable) Chilled water stage off differential.

This value is (2/3) part of the “stage off” criteria (Applies when in Cooling modes).

When the cold header leaving water temperature is less than the cold-water set point, by the difference of this value, then

the “stage off timer” will start.

Hot Delta: (Adjustable) Hot water stage off differential.

This value is (2/3) part of the “stage off” criteria (Applies when in Heating modes).

When the hot header leaving water temperature is greater than the hot water set point, by the difference of this value, then

the “stage off timer” will start.

Timer Setpoint: (Adjustable) This value is (3/3) part of the stage OFF criteria.

This timer will start when the enabled units, meet the criteria to “stage off” is met. When the timer expires, the unit with the

most amount of runtime will be disabled by the HSC.

Time Remaining: (Non-Adjustable) This value is (3/3) part of the “stage off” criteria.

The remaining time left of the “stage off timer” to disable the unit with the most amount of runtime.

Runtime: A calculated value that indicates the amount of time the compressors are operating.

Capacity SP: This value changes (from 0-100%) depending on the demand of the unit.

Circuit A/B: Compressor Off/On status Alarms Settings Displays alarm status and provides the ability to reset and change thresholds to adjust system alarms.

HMI Screens cont.

24


HMI Screens cont.PID Controller ScreenThe HSC logic control method utilizes internal PID (proportional integral derivative) algorithms. The PID controls a feedback

loop to maintain a temperature setpoint. NOTE: Please consult with our technical support team if further PID fine-tuning is

desired.

25


HMI Screens cont.

Alert Settings ScreenDisplays alert status and provides the ability to reset and change thresholds to adjust system alerts.

StatusSystem Maintenance: Provides an alarm, to remind building operator to check and clean strainers. This requires a hard reset

from this screen.

Header Temp Sensor: Provides a status if any header rack temperature sensors are out of range or offline. (True (Alarm) if

sensor out of range and False (Normal) if sensors are within range) Sensor would need to be repaired/replaced immediately

if sensor is not properly working.

Header High Temp: This point will monitor the entering hot water header temperature and will send a True/False alarm if

temp is too high.

Header Low Temp: This point will monitor the entering cold-water header temperature and will send a True/False alarm if

temp is too low.

Setpoints/ResetsMaintenance Reset: Provides a way to reset the alarm, after the building operator checks and cleans strainers to the unit.

This is a hard reset from this screen.

Scheduled Maintenance Setpoint: An adjustable timeframe, to remind building operator to check and clean strainers.

Header Hot EWT Threshold: This point will monitor the entering hot water header temperature and will send a True/False

alarm if temperature is too high.

Header Cold EWT Threshold: This point will monitor the entering cold-water header temperature and will send a True/

False alarm if temperature is too high.

26


HMI Screens cont.

Configuration Screen

System Unit Count: The number of modular units banked together and installed in the system.

VFD Logic Enabled: Selection between local (Disabled or False) and network (Enabled or True) determination of variable

speed compressor target operating capacity. When this point is Enabled the variable speed compressor target capacity

is set by the “capacity set point” in the staging software logic, and the fixed compressor control set by a Y2 call from the

staging software logic, which takes priority over the internal control values based on total system target operating capacity.

Lead Lag Enabled: Selection of Enabling (True) or Disabling (False) of compressor lead lag operation by internal

compressor control logic. This variable does not work with a variable speed applications.

Network Control: Indication that system is under network control. This value should be set by BAS because when system is

under network control many local commands and settings will not work.

27


HMI Screens cont.

BACnet/MSTP Configuration Screen Building Automation – RS485-2 {Com 2}

This section is for the BAS to configure the HSC to tie into the Automation System via Mstp.

To Local Units – RS485-1 {Com 1}This section is for the Startup Tech to configure the HSC to communicate to the Module Units.

Building Automation – IP-en0 {Primary}This section is for the BAS to configure the HSC to tie into the Automation System via IP.

Local Units Enabled – RS485-1 {Com 1}This section is for the Startup Tech to configure the HSC to communicate to the Module Units.

Network Number: The network number should be defaulted at 8100 for the local units. It can be configured to integrate per

building automation system contractor.

Object ID: The object ID is a read only status on the HMI. However, can be adjusted by a factory technician.

Baud Rate: Selectable from several speeds.

Address: Unique MAC Address

Max Master: Highest network number available.

28


HMI Screens cont.

Reboot ScreenReboot The Controller – The reboot process can take up to 10 minutes and should not be interrupted.

29


HMI Screens Layout

PID Controller

System Configuration

HydroLink2 Supervisory Control Panel HMI

Header Rack Settings

Temperature Control Settings

Manual Operations

Capacity Settings

Chiller Manual Commands

HydroLink Supervisory Control Panels “System Configuration” should be completed by a factory trained start-up tech to ensure proper operation.

BacNet/MSTP Configuration

Reboot Controller

System

Alert Settings

Configuration

HydroLink Controller

HydroLink2 Login Screen

System

Settings

Header Rack

Overview

30


Change HSC Network IP Address1. To change the Ip address on the HSC via the HMI, Swipe upward from the bottom of the tablet on any screen.

2. Press the (black colored, white trimmed, circle shaped) “Home” button to return to the home screen.

3. Press the (6-black dots inside a white circle shape) “App” button

4. Open up Google Chrome web browser and enter the HSC Ip address in the web address bar.

5. Enter the proper credentials listed below:

UN: user

PW: Networkip

6. Press the “Login” button to login to the HSC Tcp Ip Platform Service Plugin.

7. Proceed to change the “en0” port, which is the primary port.

31


Change HSC Network IP Address cont.

8. Once the new Ip address has been entered, scroll to the bottom of the screen and click “SAVE.”

9. Then, the system will need to reboot to make the changes. It will prompt you to continue, Click “OK”

10. The system will take up to 10 minutes to reboot and start up. Be patient. Then return to the “Home” screen on the HMI

and launch the HydroLink app.

32


Powering on HMIPower up the Android Tablet Interface by pressing and holding the “Power” button. While the tablet is booting up, the

screen will go blank for a minute, wait for the HMI to display the “Initializing Screen.” During this time, the tablet is connect-

ing to the HSC via Wi-Fi router located in the Supervisor Control Panel.

The HMI will display the picture above during the initializing process. While initializing, it will perform the following func-

tions:

1) Enable Wi-Fi adapter

2) Connect to wireless access point

3) Connect to Supervisory HydroLink 2 Controller. When the tablet has completed initializing, it will automatically login the

HSC’s Home screen.

NOTE: If the tablet is not successful in connecting to the HSC, the page displayed above will indicate which step failed.

Then document the “failed step” and begin to troubleshoot the issue. If the tablet will not connect to the HSC, refer to the

“HMI Rebooting” section of this manual for help reconfiguring the HMI.

33


Login Screen (Pre Factory Tech Startup) First Time ConnectingNOTE: When powering up the HMI for the first time, the “System Login” screen will look like the picture above. The entire navigation bar (at the top of screen) are disabled. At this point, contact the manufacture to schedule a required Factory Tech Startup for your system. During startup, the Technician will need to complete the “Configuration Setup” and safely start the chillers. After the configuration setup is complete, the “System Login” screen will display an Enabled “System” button that will allow the user to view the system operating status.

34


Application Example: Four Pipe Standard Header Rack

with Fixed Capacity Scroll Dedicated Chiller

35


The application of this system allows it to be applied in a wide range of two pipe hydronic systems where either chilled or hot water production is controlled through the Building Automation System (BAS). Because this system is dedicated to exclusively deliver either chilled water only or hot water only, water is not mixed within the header rack.

Cooling Only operation is based on a chilled water temperature set point with the source connected to a Net Energy Wa-

ter Loop to reject the heat of compression. Upon sensing that the leaving chilled water temperature has risen above the

set point plus dead band value, the first unit module is placed into operational mode. The first stage compressor enable

command is provided after a 90 second delay allowing the internal motorized water valve to fully open. The compressor

Proportional Integral & Differential (PID) control begins to stage “up” or “down” based upon the leaving chilled water tem-

perature in the header rack.

An optional field provided and installed chilled water storage tank may be used in applications that require additional water

volume due to the system piping. In this case, a field installed chilled water temperature sensor is installed in the storage

tank to control the unit modular chiller’s compressor staging operation. The temperature sensor located in the chilled water

temperature header rack will be ignored for control, but will be monitored.

In the application of Heating Only, production of hot water is the primary mode while chilled water is the uncontrolled

byproduct of the process. Upon sensing that the leaving hot water temperature has dropped below the set point plus dead

band value, the first unit module is placed into operational mode. The first stage compressor enable command is provided

after a 90 second delay allowing the internal motorized water valve to fully open. The compressor Proportional Integral &

Differential (PID) control begins to stage “up” or “down” based upon the leaving hot water temperature in the header rack.

An optional field provided and installed hot water storage tank may be used in applications that require additional water

volume due to the system piping. In this case, a field installed hot water temperature sensor is installed in the storage tank

to control the modular chiller’s compressor staging operation. The temperature sensor located in the hot water temperature

header rack will be ignored for control, but will be monitored.

The supervisory controller comes standard configured for Cooling Only operation. The operating mode can only be

changed from Cooling Only to Heating Only by a factory technician at the time of system commissioning.

Four Pipe Standard Pipe Rack Option using chiller only modules

System Operation Sequences: Four Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

36


Controller ConfigurationThe communications links (RS-485 and Ethernet) may be field configured for setting an address, device instance and baud

rate where applicable. The staging can be scaled in the field to support 2 to 10 stages of compressor capacity. The run time

equalization feature may be enabled or disabled in the field.

Operator FunctionsThe local display will support multiple access level users to allow read-only, Building User/Owner, and factory admin-level

access. The Building User/Owner will be able to adjust the operating temperature set point, enable/disable the system,

reset lockout alarms, and view detailed unit summaries.

Water ControlOne of the primary functions of the supervisory controller is to manage the water flow through the modular chiller plant

to maintain efficient system water circulation. When the system is enabled, the 2-way water isolation valve on a single

specified unit module will be commanded open so that the water can circulate. When the staging algorithm starts the first

unit module in the sequence, then the isolation valve that was opened for circulation will be allowed to close again and will

remain closed until the associated unit is commanded on or until all other isolation valves have closed—provided that the

System Enable command is still ON.

Optional Bypass Control: The optional bypass control is available to prevent dead heading of the system water circulating

pumps in a variable volume system when all of the unit modules water control valves are closed and is recommended for

use with all piping header racks. When the system is enabled, the 2-way water bypass valve will be commanded open so

that the water can circulate through the bypass. When the staging algorithm starts the first unit module in the sequence,

then the bypass valve that was opened for circulation will be allowed to close again and will remain closed until all other

unit module isolation valves have closed.

LABEL*LABEL **(PART NUMBER)

TEMPERATURE SENSOR

TEMPERATURE SENSOR

UNIT SIDE

UNIT SIDE

PRESSURE TRANSDUCER **

PRESSURE TRANSDUCER ***

OUTLET

INLET

Functions: Four Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

37


Temperature Control

Another primary function of the supervisory controller is to provide control of the water temperature by staging on or off

the compressors in the array of chillers based upon the commanded temperature set point communicated over the BAS.

The compressor staging PID algorithm compares the chiller plant leaving water temperature*, trending over an adjustable

time period, to the commanded water temperature set point in order to determine system demand. The sequencing logic

will respond to changes in the system demand by initiating or terminating compressor “enable” or “disable” commands to

the unit module(s). If the demand is increasing and crosses the threshold for starting another compressor, the sequenc-

ing logic will select and enable the unit module with the least amount of accumulated compressor run time and then issue

an “enable” command to the compressor with the lowest run time. In the event that a unit module is already operating a

lead compressor, the controller will issue an “enable” command to the lag compressor of that unit module. As the system

demand decreases and crosses the threshold for halting compressor operation, the sequencing logic will issue a “disable”

command to the compressor with the highest run time.

* Optional entering water temperature control available as an engineering special; contact factory.

Chilled Water Reset Function: a customer supplied external signal commanded over the BAS that shifts the chilled water

temperature set point higher from 0 - 10°F to maximize plant efficiency.

Hot Water Reset Function: a customer supplied external signal commanded over the BAS that shifts the hot water tem-

perature set point lower from 0 - 10°F to maximize plant efficiency.

Load Limit Function: a customer supplied external signal commanded over the BAS (0-100%) that limits the number of

compressors that are available to be staged in order to limit electrical consumption of the central chiller plant.

Run Time Equalization

A run time equalization feature can be enabled or disabled. Run time is per unit module, and is the combined run time of

both compressors in the unit. If the run time equalization feature is enabled, when an additional unit module is needed for

increased capacity, the next compressor call will be issued to the unit with the lowest run time of the inactive unit modules.

In the event of a lock-out fault on a compressor, the staging algorithm will bypass that unit module and use the one with

the next lowest run time. Units with faulted compressors will be placed at the back of the line in the sequencing order. This

will still allow single compressor operation if one of the two compressors is disabled.

System Notifications and Failure Alarms

The supervisory controller monitors the operation of each unit module within the chiller plant, but also monitors a number

of system functions in order to provide notification and or alarms over the BAS.

Scheduled Maintenance Notification: General system notification based upon accumulated run hours.

Sensor Failure Alarm: Controlling water temperature sensor failure shuts down system and initiates alarm. All other sensors

will only initiate an alarm.

High Condenser Temperature Alarm: Adjustable alarm point based upon entering condenser/net energy water loop tem-

perature at chiller.

Low Evaporator Temperature Alarm: Adjustable alarm point based upon leaving chilled water temperature at chiller.

Remote Stop Alarm: Alarm that the chiller plant operation has been halted by a BAS command.

Emergency Stop Alarm: Provides notification that the operation of a single unit module has been halted as a result of an

operator depressing the unit’s emergency shut down push button. Can be configured, by a factory technician at the time of

system commissioning, to halt entire system operation and initiate alarm in the event that a single unit module’s emergency

shut down push button has been depressed.

Refrigerant Monitor Alarm (Field Provided and Wired): Upon receiving an input from a refrigerant monitor, the entire sys-

tem operation is halted and initiates an additional system alarm.

Functions: Four Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

38


Control Inputs and Outputs: Four Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

System Network InputsCooling Only Mode

• “Hand/Off/Auto” Selection

• Plant “Enable”/”Disable” Command

• Plant Mode Command (“Cooling”)

• Chilled Water Temperature Set Point

• Differential Water Pressure Set Points (optional: chilled water/source/net energy water)

• Chilled Water Temperature Reset (optional)

• Load Limiting Status (optional)

• Remote Plant Shutdown (optional)

Heating Only Mode



• Plant Mode Command (“Heating”)

• Hot Water Temperature Set Point


• Hot Water Temperature Reset (optional)



System Control OutputsThe Niagara Direct Input Output Module features digital and analog outputs to provide control of relays and speed refer-

ence outputs on VFDs or positioning outputs on modulating actuators.

Cooling Only Mode

• Alarm Relay/Annunciator (optional)

• Remote Chilled Water Pump Speed Reference

• Chilled Water Bypass Valve*

• Remote Source/Net Energy Water Pump Speed Reference

• Source/Net Energy Water Bypass Valve*

*Field installed in bypass header assembly if system configured for water bypass

Heating Only Mode


• Remote Hot Water Pump Speed Reference

• Hot Water Bypass Valve*




39


Control Inputs and Outputs: Four Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

System Network Outputs Cooling Only Mode

• Entering Chilled Water Temperature

• Leaving Chilled Water Temperature

• Estimated Chilled Water Flow Rate

• Chilled Water Bypass Valve Position*

• Estimated Chilled Water Plant Load

• Entering Source/Net Energy Water Loop Temperature

• Leaving Source/Net Energy Water Loop Temperature

• Estimated Source/Net Energy Water Flow Rate

• Source/Net Energy Water Bypass Valve Position*

• Estimated Source/Net Energy Water Plant Load

• Active Module(s)

• Active Compressor(s)

• Active System and Unit Module Alarm(s)


Heating Only Mode

• Entering Hot Water Temperature

• Leaving Hot Water Temperature

• Estimated Hot Water Flow Rate

• Hot Water Bypass Valve Position*

• Estimated Hot Water Plant Load










40


Application Example: Four Pipe Reversing Header Rack with Fixed Capacity Scroll

Dedicated Chiller

41


The application of this system allows it to be applied in a wide range of two pipe hydronic systems where chilled or hot

water production is controlled through the Building Automation System (BAS). This system utilizes the three way water

control valves within the header rack to reverse the water flow through the evaporator and condenser which allows water

to be mixed within the system.

Cooling operation is based on a chilled water temperature set point with the source connected to a Net Energy Water Loop

to reject the heat of compression. Upon sensing that the leaving chilled water temperature has risen above the set point

plus dead band value, the first unit module is placed into operational mode. The first stage compressor enable command

is provided after a 90 second delay allowing the internal motorized water valve to fully open. The compressor Proportional

Integral & Differential (PID) control begins to stage “up” or “down” based upon the leaving chilled water temperature in the

header rack.



tank to control the modular chiller’s compressor staging operation. The temperature sensor located in the chilled water

temperature header rack will be ignored for control, but will be monitored.

During Heating operation, the three-way water valves in the header rack are energized to reverse the flow of water through

the unit module in order to produce hot water. Upon sensing that the leaving hot water temperature has dropped below

the set point plus dead band value, the first unit module is placed into operational mode. The first stage compressor enable


Proportional Integral & Differential (PID) control begins to stage “up” or “down” based upon the leaving hot water tempera-

ture in the header rack.



to control the modular chiller’s compressor staging operation. The temperature sensor located in the hot water temperature


Four Pipe Reversing Pipe Rack Option using chiller only modules

System Operation Sequences: Four Pipe Reversing Header Rack with Fixed Capacity Scroll Dedicated Chiller

42


Controller Configuration

The communications links (RS-485 and Ethernet) may be field configured for setting an address, device instance and baud



Operator Functions

The local display will support multiple access level users to allow read-only, Building User/Owner, and factory admin-level

access. The Building User/Owner will be able to adjust the operating temperature set point, “enable/disable the system,


Water Control

One of the primary functions of the supervisory controller is to manage the water flow through the modular chiller plant to

maintain efficient system water circulation. When the system is enabled, the 2-way water isolation valve on a single speci-

fied unit module will be commanded open so that the water can circulate. When the staging algorithm starts the first unit

module in the sequence, then the isolation valve that was opened for circulation will be allowed to close again and will








unit module isolation valves have closed


TEMPERATURE SENSOR

TEMPERATURE SENSOR

UNIT SIDE

UNIT SIDE



OUTLET

INLET

Functions: Four Pipe Reversing Header Rack with Fixed Capacity Scroll Dedicated Chiller

43


Temperature Control










































Functions: Four Pipe Reversing Header Rack with Fixed Capacity Scroll Dedicated Chiller

44


System Network InputsCooling Mode









Heating Mode











Cooling Mode







Heating Mode







Control Inputs and Outputs: Four Pipe Reversing Header Rack with Fixed Capacity Scroll Dedicated Chiller

45


System Network Outputs Cooling Mode















Heating Mode















Control Inputs and Outputs: Four Pipe Reversing Header Rack with Fixed Capacity Scroll Dedicated Chiller

46


Application Example: Four Pipe Standard Header Rack with Fixed Capacity Scroll

Reversible Chiller

47


The operation of this system allows it to be applied in a wide range of two pipe hydronic systems where the system change over between cooling and heating is controlled through the Building Automation System (BAS). Because this system uti-lizes refrigerant reversing valves within the reversible chiller, water is not mixed within the header rack.

Cooling operation based on a chilled water temperature set point with the source connected to a Net Energy Water Loop

to reject the heat of compression. Upon sensing that the leaving chilled water temperature has risen above the set point

plus dead band value, the first unit module is placed into operational mode. The first stage compressor enable command

is provided after a 90 second delay allowing the internal motorized water valve to fully open. The compressor Proportional


header rack.



tank to control the modular chiller’s compressor staging. The temperature sensor located in the chilled water temperature


During Heating operation, the refrigerant reversing valve is energized so that the flow of refrigerant changes within the

unit module in order to produce hot water. Upon sensing that the leaving hot water temperature has dropped below the

set point plus dead band value, the first unit module is placed into operational mode. The first stage compressor enable


Proportional Integral & Differential (PID) control begins to stage “up” or “down” based upon the leaving hot water tempera-

ture in the header rack.



to control the modular chiller’s compressor staging. The temperature sensor located in the hot water temperature header

rack will be ignored for control, but will be monitored.

Four Pipe Standard Pipe Rack Option using reversible chiller modules

System Operation Sequences: Four Pipe Standard Header Rack with Fixed Capacity Scroll Reversible Chiller

48






Operator Functions


access. The Building User/Owner will be able to adjust the operating temperature set point, “enable/disable the system,


Water Control














TEMPERATURE SENSOR

TEMPERATURE SENSOR

UNIT SIDE

UNIT SIDE



OUTLET

INLET

Functions: Four Pipe Standard Header Rack with Fixed Capacity Scroll Reversible Chiller

49


Temperature Control


























System Notifications and Failure Alarms The supervisory controller monitors the operation of each unit module within the chiller plant, but also monitors a number















Functions: Four Pipe Standard Header Rack with Fixed Capacity Scroll Reversible Chiller

50


Control Inputs and Outputs: Four Pipe Standard Header Rack with Fixed Capacity Scroll Reversible Chiller

System Network InputsCooling Mode









Heating Mode











Cooling Mode







Heating Mode







51


Control Inputs and Outputs: Four Pipe Standard Header Rack with Fixed Capacity Scroll Reversible Chiller

System Network Outputs Cooling Mode















Heating Mode















52


Application Example: Six Pipe Dedicated Header Rack with Reversible Chiller

53


The operation of this system allows it to be applied in a wide range of two pipe hydronic systems where the system change over between cooling and heating is controlled through the Building Automation System (BAS). Because this system uti-lizes refrigerant reversing valves within the reversible chiller, water is not mixed within the header rack.

Cooling operation is based upon a chilled water temperature set point with the chillers load heat exchanger fully opened

to the chilled water piping and its source (condenser) heat exchanger fully open to the Net Energy Water Loop piping to

reject the heat of compression. Upon sensing that the leaving chilled water temperature has risen above the set point plus

dead band value, the first unit module is placed into operational mode. The first stage compressor enable command is

provided after a 90 second delay allowing the internal motorized water valve to fully open. The compressor Proportional


header rack.





Heating operation is based upon a hot water temperature set point with the chillers load heat exchanger fully opened to

the hot water piping and its source (evaporator) heat exchanger fully open to the Net Energy Water Loop piping to extract

heat. Upon sensing that the leaving hot water temperature has dropped below the set point plus dead band value, the

refrigerant reversing valves of the first unit module are energized to place the unit into the heating operational mode. The

first stage compressor enable command is provided after a 90 second delay allowing the internal motorized water valve to

fully open. The compressor Proportional Integral & Differential (PID) control begins to stage “up” or “down” based upon the

leaving hot water temperature in the header rack.





Six Pipe Dedicated Pipe Rack Option using reversible chiller modules

System Operation Sequences: Six Pipe Dedicated Header Rack with Reversible Chiller

54






Operator Functions




Water Control














TEMPERATURE SENSOR

TEMPERATURE SENSOR

UNIT SIDE

UNIT SIDE



OUTLET

INLET

Functions: Six Pipe Dedicated Header Rack with Reversible Chiller

55


Temperature Control










































Functions: Six Pipe Dedicated Header Rack with Reversible Chiller

56


Control Inputs and Outputs: Six Pipe Dedicated Header Rack with Reversible Chiller

System Network InputsSix Pipe Header Rack Configuration



• Plant Mode Command (“Cooling” or “Heating”)






• Load Limiting Status (optional – applies equally to cooling & heating)



System Control Outputs

Six Pipe Header Rack Configuration









57


Control Inputs and Outputs: Six Pipe Dedicated Header Rack with Reversible Chiller

System Network Outputs

Six Pipe Header Rack Configuration




















58


Application Example: Six Pipe Standard Header Rack with Fixed Capacity Scroll

Dedicated Chiller

59


The operation of this system allows it to be applied in a wide range of four pipe hydronic systems where the system change over between cooling and heating can be controlled either through the Building Automation System (BAS) or allowed to operate as a heat recovery chiller utilizing the units Aurora HydroLink controls. This system utilizes the three way water control valves within the header rack to reverse the water flow through the evaporator, condenser and Net Energy Water Loop which allows water to be mixed within the system.

Primary Cooling operation is based upon a chilled water temperature set point with the chillers evaporator fully opened

to the chilled water piping and its condenser fully open to the hot water piping to reject the heat of compression. Upon

sensing that the leaving chilled water temperature has risen above the set point plus dead band value, the first unit module

is placed into operational mode. The first stage compressor enable command is provided after a 90 second delay allowing

the internal motorized water valve to fully open. The compressor Proportional Integral & Differential (PID) control begins

to stage “up” or “down” based upon the leaving chilled water temperature in the header rack. In Primary Cooling mode the

three-way water valve will modulate the condenser water between the hot water piping and the Net Energy Water Loop in

order to maintain the hot water temperature set point.





Six Pipe Standard Pipe Rack Option using chiller only modules

System Operation Sequences: Six Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

60


Primary Heating operation is based upon a hot water temperature set point with the chillers evaporator fully opened to the

chilled water piping and its condenser fully open to the hot water piping to reject the heat of compression. Upon sens-

ing that the leaving hot water temperature has dropped below the set point plus dead band value, the first unit module is

placed into operational mode. The first stage compressor enable command is provided after a 90 second delay allowing

the internal motorized water valve to fully open. The compressor Proportional Integral & Differential (PID) control begins

to stage “up” or “down” based upon the leaving hot water temperature in the header rack. In Primary Heating mode the

three-way water valve will modulate the evaporator water between the chilled water piping and the Net Energy Water Loop

in order to maintain the chilled water temperature set point.





The standard operational mode for the supervisory controller is Full Building Auto which is utilized to determine which of

the two loads, cooling or heating, is greater to establish a Primary mode. In this mode, the three-way water valves are po-

sitioned such that the chillers evaporator is fully open to the chilled water piping and the condenser is fully open to the hot

water piping. When the system is enabled, the unit module with the least amount of accumulated run time will be placed

into Full Building Auto mode. Upon sensing that a chilled or hot water temperature has changed beyond one of the respec-

tive temperature set point plus dead band value, the first stage compressor enable command is provided after a 90 second

delay allowing the internal motorized water valve to fully open. The compressor Proportional Integral & Differential (PID)

control will stage “up” subsequent compressors and unit modules until the lesser of the two loads temperature set point

is satisfied at which point the three-way water valve will modulate open to the Net Energy Water Loop to prevent “over

shooting” the set point. It is at this time that the modular supervisory controller will place all of the unit modules into a Pri-

mary (either cooling or heating) mode of operation until the larger of the two loads temperature set point is satisfied. Once

both temperature set points have been satisfied, the modular supervisory controller then returns all of the unit modules to

Full Building Auto.

Economizer is a unique operational mode exclusively available to the six pipe standard header rack. When enabled, the

first stage of cooling will be supplied by the Net Energy Water Loop so long as the temperature is at or below the chilled

water temperature set point. Upon sensing that the leaving chilled water temperature has risen above the set point plus

dead band value, the unit module with the least amount of accumulated run time will be placed into operational mode.

The three-way water valves to the chillers evaporator will be fully opened between the chilled water and Net Energy Wa-

ter Loop piping after a 90 second delay allowing the units internal motorized water valve to fully open. The economizer

Proportional Integral & Differential (PID) control will modulate the three-way water valves proportionally as well as enable

additional unit modules economizer mode to maintain the chilled water temperature set point. When mechanical cooling is

required, the modular supervisory controller will return all of the unit modules to Full Building Auto.

Cooling Only operation is based upon a chilled water temperature set point with the chillers evaporator fully opened to

the chilled water piping and its condenser fully open to the Net Energy Water Loop to reject the heat of compression. This

commanded mode disables all other operational modes and only delivers cooling.

Heating Only operation is based upon a hot water temperature set point with the chillers evaporator fully opened to the

Net Energy Water Loop and its condenser fully open to the hot water piping to reject the heat of compression. This com-

manded mode disables all other operational modes and only delivers heating.

System Operation Sequences: Six Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

61






Operator Functions




Water Control







Bypass Control: The bypass control is to prevent dead heading of the system water circulating pumps in a variable volume

system when all of the unit modules water control valves are closed and is required for use with all six pipe standard header

racks. When the system is enabled, the 2-way water bypass valve will be commanded open so that the water can circulate

through the bypass. When the staging algorithm starts the first unit module in the sequence, then the bypass valve that

was opened for circulation will be allowed to close again and will remain closed until all other unit module isolation valves

have closed


TEMPERATURE SENSOR

TEMPERATURE SENSOR

UNIT SIDE

UNIT SIDE



OUTLET

INLET

Functions: Six Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

62


Temperature Control










































Functions: Six Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

63


Control Inputs and Outputs: Six Pipe Standard Header Rack with Fixed Capacity Scroll Dedicated Chiller

System Network InputsSix Pipe Header Rack Configuration• “Hand/Off/Auto” Selection


• Plant Mode Command (“Primary Cooling” / “Primary Heating” / “Full Building Auto”)






• Load Limiting Status (optional – applies equally to cooling & heating)



System Control Outputs

Six Pipe Header Rack Configuration • Alarm Relay/Annunciator (optional)







*Field installed in bypass header assembly

System Network Outputs

Six Pipe Header Rack Configuration • Entering Chilled Water Temperature


















*Field installed in bypass header assembly

64


Unit Status

Compressor Fault Status

1 = Normal

2 = Alarm

3 = Shutdown

4 = Load Shed A

5 = Load Shed B

6 = Load Shed A & B

7 = AXB A Communication Loss

8 = AXB B Communication Loss

9 = AXB A & B Communication Loss

10 = ABC A Communication Loss

11 = ABC B Communication Loss

12 = ABC A & B Communication Loss

13 = ABC A & ABC B DIP Switch Mismatch

14 = Load Entering Water Temperature Alarm

15 = Load Leaving Water Temperature Alarm

16 = Source Entering Water Temperature Alarm

17 = Source Leaving Water Temperature Alarm

1 = Normal

2 = E1-Input Error

3 = E2-High Pressure

4 = E3-Low Pressure

5 = E4-Freeze Protection 2

6 = E5-Freeze Protection 1

7 = E6-Loss of Charge

8 = E7-Condensate

9 = E8-Over/Under Voltage

11 = E10-Compressor Monitor

14 = E13-AXB Sensor Error - Non Critical

15 = E14-AXB Sensor Error - Critical

17 = E16-Variable Speed Pump Error

19 = E18-Non Critical Comm Error

20 = E19-Critical Comm Error

21 = E20-Loss of Communications

22 = E21-Low Loop Pressure

24 = E23-HA1 Fault

25 = E24-HA2 Fault

27 = E26-Entering Source Water Low Limit

28 = E27-Entering Source Water High Limit

29 = E28-Leaving Source Water Low Limit

30 = E29-Leaving Source Water High Limit

32 = E31-Source Flow

33 = E32-Load Flow

HydroLink2 Aurora Control Codes

65


HMI Reloading/Rebooting ProcedureThe following document should be referenced if the HydroLink 2 HMI tablets do not connect and communicate properly to

the HydroLink 2 Controllers. This will guide you through the process of reconfiguring the router and the HMI.

1. Power on the tablet by pressing and holding the power button until the tablet turns on.

2. If the tablet connects to the HydroLink 2 Supervisory Controller, the following steps should be skipped. If it does not

connect, the following screens may be displayed.

Fails to connect to wireless access point1. Make sure the switch on the bottom of the router is set to “AP-Router”.

2. Make sure the Micro SD card is inserted into the tablet.

a. *Do not proceed if Micro SD Card is not inserted.

3. Swiping up from the bottom of the screen will make a tool bar appear at the bottom of the screen, use the“ “ button

to navigate to the tablets home page.

a. Press the Apps button on the home page to navigate to the Apps page.

b. On the Apps page, locate the HydroLink 2 app and press and hold the icon until it can be uninstalled by

moving it to the trash can on the top of the page, and confirm the uninstall.

c. Follow the same steps to uninstall the 123Go app if it is installed on the tablet.

d. Return to the Home page.

4. From the home screen press the File manager Icon and navigate to the following location:

5. Installing Applications a. Select “File Manager” from the home screen. b. Select “SD Card” c. Select “HydroLink 2” d. Select 123GOXX-XX.apk. The XX-XX is the version number ex. 01-00. i. When popup appears select “NEXT”, then select “INSTALL”.

ii. Once the install is complete, select “OPEN”.

66


HMI Reloading/Rebooting Procedure cont.6. Router Setup will begin automatically.

a. Follow on-screen prompts for Router Setup.

i. Once the tablet is connected to the router, the Factory Initialization screen will be displayed.

ii. Wait for HMI popup.

1. Select “NEXT”

2. Select “INSTALL”

3. Select “ACCEPT”

4. Once App is installed select “DONE”

iii. Doc View popup

1. Select “INSTALL”

2. Select “DONE”

3. Screen should turn green

4. Touch anywhere on the green screen.

5. The 123 Go prompt will appear asking if you want to uninstall.

6. Select “OK”

7. Once finished press at “ “at the bottom of screen to return to the HOME Screen

7. Setup Tablets Home Screen

a. Press the Apps button that is in the bottom center of the screen. The apps button is a round white button with

six dots.

b. Locate the “Doc View” icon. Press and hold the “Doc View” icon until the home screen and drop the icon onto

the home screen.

c. Repeat this process with the “HMI” app.

d. Leave the File Manager icon on the home screen.

8. Start the HMI App by pressing it one time.

67


BACnet PointslistsTR

UE

FALS

E

1M

SVSY

S_Sy

stem

Mod

eR/

WC

oolin

g O

nly

-Se

lect

ion

of c

urre

nt o

pera

ting

mod

e fo

r bot

h he

ader

rack

and

non

-hea

der r

ack

appl

icat

ions

.

1BV

SYS_

Syst

emEn

able

R/W

Dis

able

-A

llow

s su

perv

isor

to e

nabl

e/di

sabl

e un

its a

ccor

ding

to ru

ntim

e &

cap

acity

. En

able

s (T

rue)

or D

isab

les

(Fal

se) s

yste

m o

pera

tion.

Whe

n th

is s

ettin

g is

dis

able

d th

e co

mpr

esso

r out

puts

will

not

be

activ

ated

exc

ept f

or m

anua

l ove

rrid

e op

erat

ion.

Enab

leD

isab

le

2BV

SYS_

EmSh

utdo

wn

R/W

Nor

mal

-En

able

(Tru

e) o

r Dis

able

(Fal

se) E

mer

genc

y Sh

utdo

wn.

Shut

dow

nN

orm

al

3BV

SYS_

Syst

emM

aint

enan

eR

Nor

mal

-Pr

ovid

es a

n al

arm

that

will

trig

ger e

very

90

cale

ndar

day

s, to

rem

ind

owne

r to

chec

k an

d cl

ean

stra

iner

s. T

his

requ

ires

a h

ard

rese

t fro

m th

e H

MI.

Ala

rmN

orm

al

4BV

SYS_

Tem

pSen

sorF

ailu

reR

Nor

mal

-Pr

ovid

es a

n al

arm

if a

ny h

eade

r rac

k te

mpe

ratu

re s

enso

r be

out o

f ran

ge o

r offl

ine.

(T

rue(

Ala

rm) i

f sen

sor o

ut o

f ran

ge a

nd F

alse

(Nor

mal

) if s

enso

rs a

re w

ithin

rang

e)A

larm

Nor

mal

5BV

SYS_

Hig

hHea

derT

emp

RN

orm

al-

This

poi

nt w

ill m

onito

r the

ent

erin

g he

ader

flui

d te

mpe

ratu

re.

True

(Ala

rm) i

f sen

sor

out o

f ran

ge a

nd te

mp

is to

o H

IGH

, and

a F

alse

(Nor

mal

) if s

enso

rs a

re w

ithin

rang

e).

Ala

rmN

orm

al

6BV

SYS_

Low

Hea

derT

emp

RN

orm

al-

This

poi

nt w

ill m

onito

r the

ent

erin

g he

ader

flui

d te

mpe

ratu

re.

True

(Ala

rm) i

f sen

sor

out o

f ran

ge a

nd te

mp

is to

o LO

W, a

nd a

Fal

se (N

orm

al)

Ala

rmN

orm

al

7BV

SYS_

Cap

acity

Lim

it_En

able

R/W

Dis

able

-Th

is v

aria

ble

will

act

ivat

e an

d di

sabl

e th

e C

apac

ity L

imit

func

tions

.En

able

Dis

able

1A

VSY

S_C

oldS

etpo

int

R/W

45°F

2A

VSY

S_H

otSe

tpoi

ntR/

W12

5°F

3A

VSY

S_H

otSe

tpoi

ntRe

set

R/W

0°F

4A

VSY

S_C

oldS

etpo

intR

eset

R/W

0°F

5A

VSY

S_Sy

stem

Cap

acity

Lim

itR/

W-

%Th

is w

ill li

mit

the

capa

city

of t

he s

yste

m fr

om 1

00%

dow

n to

20%

(dep

endi

ng o

n nu

mbe

r of u

nits

in s

yste

m) b

y di

sabl

ing

Uni

ts a

llow

ed to

run.

Typ

ical

ly u

sed

to li

mit

ener

gy c

onsu

mpt

ion

duri

ng p

eak

hour

s.

6A

VSY

S_A

ctiv

eCap

acity

R10

0%

7A

VSY

S_Sy

stem

Tota

lCur

rent

R-

A

8A

VSY

S_Ef

fect

iveC

oldS

PR

45°F

9A

VSY

S_Ef

fect

iveH

otSP

R12

5°F

10A

VSY

S_Sy

stem

Uni

tCou

ntR

--

A to

tal c

ount

of u

nits

that

are

pip

ed to

geth

er to

mak

e up

(1) s

yste

m fo

r mor

e sy

stem

cap

acity

con

trol

.

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

Syst

em P

oint

s

Coo

ling

set p

oint

use

d fo

r sys

tem

cap

acity

con

trol

in c

oolin

g m

odes

.

Allo

ws

a re

set v

alue

com

man

d ra

ngin

g fr

om {

-6 to

6 }

to re

set t

he s

yste

m h

otw

ater

set

poin

t.

Allo

ws

a re

set v

alue

com

man

d ra

ngin

g fr

om {

-6 to

6 }

to re

set t

he s

yste

m c

oldw

ater

set

poin

t.

*Pos

sibl

e va

lues

are

list

ed b

elow

.

* A

lso

see

"Ope

ratin

g Sy

stem

Mod

es

Base

d on

Hea

der R

ack

Sele

ctio

n."

^See

tabl

e at

end

of l

ist f

or e

xam

ples

.

Hea

ting

set p

oint

use

d fo

r sys

tem

cap

acity

con

trol

in h

eatin

g m

odes

.

The

perc

enta

ge o

f uni

ts th

at a

re a

ctiv

ely

enab

led

and

runn

ing.

Tota

l am

pera

ge o

f ope

ratin

g co

mpr

esso

rs in

the

syst

em.

A c

ombi

natio

n of

the

Col

dSet

poin

t, an

d th

e C

oldS

etpo

intR

eset

, use

d fo

r sys

tem

cap

acity

con

trol

in c

oolin

g m

odes

..

A c

ombi

natio

n of

the

Hot

Setp

oint

, and

the

Hot

Setp

oint

Rese

t, us

ed fo

r sys

tem

cap

acity

con

trol

in h

eatin

g m

odes

..

68


BACnet Pointslists cont.

TRU

EFA

LSE

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

101

MSV

Ch1

_Ala

rmSt

atus

R-

-D

ispl

ays t

he c

urre

nt o

vera

ll un

it fa

ult s

tatu

s.

102

MSV

Ch1

_Uni

tSta

tus

R-

-D

ispl

ays t

he c

urre

nt o

vera

ll un

it op

erat

ing

stat

us

103

MSV

Ch1

_Com

pALo

ckou

tSta

tus

R-

-M

ost r

ecen

t fau

lt de

tect

ed b

y A

BC A

.

104

MSV

Ch1

_Com

pBLo

ckou

tSta

tus

R-

-M

ost r

ecen

t fau

lt de

tect

ed b

y A

BC B

.

101

BVC

h1_E

nabl

eMan

ualO

verr

ide

RO

ff-

Stat

us o

f Loc

al M

anua

l Ove

rrid

e at

uni

t.En

able

(On)

Dis

able

(Off)

102

BVC

h1_I

soV

alve

Stat

usR

Clo

sed

-St

atus

of A

BC A

acc

esso

ry re

lay

outp

ut.

Ope

nC

lose

d

101

AV

Ch1

_Uni

tRun

Tim

eR

-hr

Ana

log

Val

ue =

201

Bina

ry V

alue

= 2

01-2

02

Ana

log

Val

ue =

301

Bina

ry V

alue

= 3

01-3

02

Ana

log

Val

ue =

401

Bina

ry V

alue

= 4

01-4

02

Ana

log

Val

ue =

501

Bina

ry V

alue

= 5

01-5

02

** P

ossi

ble

valu

es a

re li

sted

bel

ow.

***

Poss

ible

val

ues

are

liste

d be

low

.

Com

pres

sor A

& c

ompr

esso

r B o

pera

ting

hour

s co

mbi

ned.

Mul

ti St

ate

Val

ue =

401

-404

Mul

ti St

ate

Val

ue =

201

-204

Chi

ller 1

Poi

nts

****

Pos

sibl

e va

lues

are

list

ed b

elow

.

****

Pos

sibl

e va

lues

are

list

ed b

elow

.

Chi

ller 2

Mul

ti St

ate

Val

ue =

301

-304

Mul

ti St

ate

Val

ue =

501

-504

Chi

ller 5

Chi

ller 2

- 5

will

all

have

the

sam

e po

ints

as

Chi

ller 1

.

Chi

ller 3

Chi

ller 4

TRU

EFA

LSE

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

1101

AV

HD

R_H

otBy

Pass

_Vlv

R-

%

1102

AV

HD

R_C

oldB

yPas

s_V

lvR

-%

1103

AV

HD

R_N

etEn

ergy

ByPa

ss_V

lvR

-%

1104

AV

HD

R_Sr

cHot

Out

let_

Tem

pR

-°F

1105

AV

HD

R_Sr

cHot

Inle

t_Te

mp

R-

°F

1106

AV

HD

R_Lo

adC

oldO

utle

t_Te

mp

R-

°F

1107

AV

HD

R_Lo

adC

oldI

nlet

_Tem

pR

-°F

1108

AV

HD

R_N

etEn

ergy

Out

let_

Tem

pR

-°F

1109

AV

HD

R_N

etEn

ergI

nlet

_Tem

pR

-°F

1101

BVRe

frig

eran

tMon

itorA

larm

RN

orm

al-

Mon

itors

the

Refr

iger

ant L

eak

Det

ectio

n sy

stem

(pro

vide

d by

oth

ers)

and

will

sen

d a

True

(Ala

rm)/F

alse

(Nor

mal

) ala

rm if

trig

gere

d.A

larm

Nor

mal

Syst

ems

head

er ra

ck g

eo w

ater

out

let t

empe

ratu

re.

Syst

ems

head

er ra

ck g

eo w

ater

inle

t tem

pera

ture

.

Syst

ems

head

er ra

ck h

ot/s

ourc

e w

ater

inle

t tem

pera

ture

.

Syst

ems

head

er ra

ck c

old/

load

wat

er o

utle

t tem

pera

ture

.

Syst

ems

head

er ra

ck h

ot/s

ourc

e w

ater

out

let t

empe

ratu

re.

Syst

ems

head

er ra

ck c

old/

load

wat

er in

let t

empe

ratu

re.

Syst

ems

head

er ra

ck g

eo w

ater

byp

ass

valv

e.

(Pro

port

iona

l with

6pi

pe 3

way

val

ves d

epen

ding

on

mod

e).

Syst

ems

head

er ra

ck c

old/

load

wat

er b

ypas

s va

lves

. (P

ropo

rtio

nal w

ith lo

ad/e

vapo

rato

r 6pi

pe 3

way

val

ves)

.

Hea

der R

ack

Onb

oard

34-

IO

Syst

ems

head

er ra

ck h

ot/s

ourc

e w

ater

byp

ass

valv

e. (P

ropo

rtio

nal w

ith s

ourc

e/co

nden

ser 6

pipe

3w

ay v

alve

s).

69


TRU

EFA

LSE

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

*M

SV-1

SYS_

Mod

eR/

W-

-

**

MSV

- 10

1

201

30

1

401

50

1

Ala

rmSt

atus

R-

-

Ala

rm S

tatu

s

Syst

em M

ode

Dis

play

s the

cur

rent

ove

rall

unit

faul

t sta

tus.

Pos

sibl

e va

lues

are

:1

= N

orm

al2

= A

larm

3 =

Shut

dow

n4

= Lo

ad S

hed

A5

= Lo

ad S

hed

B6

= Lo

ad S

hed

A &

B7

= A

XB A

Com

mun

icat

ion

Loss

8 =

AXB

B C

omm

unic

atio

n Lo

ss9

= A

XB A

& B

Com

mun

icat

ion

Loss

10 =

ABC

A C

omm

unic

atio

n Lo

ss11

= A

BC B

Com

mun

icat

ion

Loss

12 =

ABC

A &

B C

omm

unic

atio

n Lo

ss13

= A

BC A

& A

BC B

DIP

Sw

itch

Mis

mat

ch14

= L

oad

Ente

ring

Wat

er T

empe

ratu

re A

larm

15 =

Loa

d Le

avin

g W

ater

Tem

pera

ture

Ala

rm16

= S

ourc

e En

teri

ng W

ater

Tem

pera

ture

Ala

rm17

= S

ourc

e Le

avin

g W

ater

Tem

pera

ture

Ala

rm

Poss

ible

val

ues

are:

1 =

Syst

em O

ff- w

ith Is

olat

ion

valv

es o

pen

2 =

Coo

ling

only

- (S

tand

ard)

3 =

Hea

ting

only

- (S

tand

ard)

4 =

Aut

o fu

ll bu

ildin

g - (

6-Pi

pe H

eade

r Rac

k)5

= Fu

ll bu

ildin

g - (

Stan

dard

)6

= Pr

imar

y co

olin

g - (

6-Pi

pe H

eade

r Rac

k)7

= Pr

imar

y he

atin

g - (

6-Pi

pe H

eade

r Rac

k)8

= Sy

stem

Off-

with

Isol

atio

n va

lves

clo

sed


70


TRU

EFA

LSE

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

***

MSV

- 10

2

202

30

2

402

50

2

Uni

t_St

atus

R-

-

Uni

t Sta

tus

Dis

play

s the

cur

rent

ove

rall

unit

oper

atin

g st

atus

. Po

ssib

le v

alue

s ar

e:1

= St

andb

y3

= Si

ngle

Com

pres

sor C

oolin

g4

= Bo

th C

ompr

esso

rs C

oolin

g6

= Si

ngle

Com

pres

sor H

eatin

g7

= Bo

th C

ompr

esso

rs H

eatin

g10

= E

mer

genc

y Sh

utdo

wn

11 =

Loa

d Sh

ed12

= L

ocko

ut A

13 =

Tes

t Mod

e15

= L

ocko

ut B

18 =

Sin

gle

Com

pres

sor w

/Loc

kout

19 =

Ful

l Loc

kout

31 =

Sou

rce

Flow

Sw

itch

Faul

t32

= L

oad

Flow

Sw

itch

Faul

t33

= L

oad

& S

ourc

e Fl

ow S

witc

h Fa

ult


71


TRU

EFA

LSE

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

****

MSV

- 10

3-10

4

203-

204

30

3-30

4

403-

404

50

3-50

4

Com

pLoc

kout

Stat

usR

--

^A

V-5

SYS_

Syst

emC

apac

ityLi

mit

R/W

--

Syst

em C

apac

ity L

imit

Com

pres

sor L

ocko

ut S

tatu

s

Mos

t rec

ent f

ault

dete

cted

by

ABC

B.

Poss

ible

val

ues

are:

1 =

Nor

mal

2 =

E1-I

nput

Err

or3

= E2

-Hig

h Pr

essu

re4

= E3

-Low

Pre

ssur

e5

= E4

-Fre

eze

Prot

ectio

n 2

6 =

E5-F

reez

e Pr

otec

tion

17

= E6

-Los

s of

Cha

rge

8 =

E7-C

onde

nsat

e9

= E8

-Ove

r/U

nder

Vol

tage

11 =

E10

-Com

pres

sor M

onito

r14

= E

13-A

XB S

enso

r Err

or -

Non

Cri

tical

15 =

E14

-AXB

Sen

sor E

rror

- C

ritic

al17

= E

16-V

aria

ble

Spee

d Pu

mp

Erro

r19

= E

18-N

on C

ritic

al C

omm

Err

or20

= E

19-C

ritic

al C

omm

Err

or21

= E

20-L

oss

of C

omm

unic

atio

ns22

= E

21-L

ow L

oop

Pres

sure

24 =

E23

-HA

1 Fa

ult

25 =

E24

-HA

2 Fa

ult

27 =

E26

-Ent

erin

g So

urce

Wat

er L

ow L

imit

28 =

E27

-Ent

erin

g So

urce

Wat

er H

igh

Lim

it29

= E

28-L

eavi

ng S

ourc

e W

ater

Low

Lim

it30

= E

29-L

eavi

ng S

ourc

e W

ater

Hig

h Li

mit

32 =

E31

-Sou

rce

Flow

33 =

E32

-Loa

d Fl

ow

Capa

city

Limi

ted

2 Ch

iller

Sys

tem

3-Ch

iller

Sys

tem

4-Ch

iller

Sys

tem

5-Ch

iller

Sys

tem

1-Un

it 50

%33

%25

%20

%

2-Un

its10

0%66

%50

%40

%

3-Un

its-

100%

75%

60%

4-Un

its

--

100%

80%

5-Un

its-

--

100%

Syste

m C

apac

ity L

imit

Exam

ples


72


TRU

EFA

LSE

Stat

e Te

xtO

bjec

t ID

Obj

ect

Type

Obj

ect N

ame

Rea

d /

Wri

teD

efau

lt V

alue

Uni

tsD

escr

iptio

n

Ope

ratin

g Sy

stem

Mod

es B

ased

on

Hea

der R

ack

Sele

ctio

n

12

34

56

78

( OFF

)

Iso

Op

enC

ooli

ng

On

lyH

eati

ng

On

ly(A

uto

)

Full

Bu

ild

ing

Full

Bu

ild

ing

Pri

mar

y

Coo

lin

gP

rim

ary

H

eati

ng

( OFF

)

Is

o C

lose

d

1Se

lect

Ch

ille

r T

yp

e:-

--

--

--

--

--

24

Pip

e St

and

ard

Non

-Rev

ersi

ng

Com

pre

ssor

sH

ot/C

old

2,3,

5Y

esY

esY

esN

AY

esN

AN

AY

es

34

Pip

e R

ever

sin

gN

on-R

ever

sin

g C

omp

ress

ors

Loa

d2,

3,5

Yes

Yes

Yes

NA

Yes

NA

NA

Yes

46

Pip

e St

and

ard

Non

-Rev

ersi

ng

Com

pre

ssor

sH

ot/C

old

AL

LY

esY

esY

esY

esY

esY

esY

esY

es

56

Pip

e D

edic

ated

Sou

rce

Rev

ersi

ng

Com

pre

ssor

sH

ot/C

old

2,3

Yes

Yes

Yes

NA

NA

NA

NA

Yes

64

Pip

e St

and

ard

Rev

ersi

ng

Com

pre

ssor

sL

oad

2,3,

5Y

esY

esY

esN

AY

esN

AN

AY

es

7N

o H

ead

er R

ack:

--

--

--

--

--

-

Mod

e (7

)-P

rim

ary

Hea

ting

: T

he

syst

em w

ill o

per

ate

in M

ode

(3)-

Hea

ting

Onl

y. U

nit

s w

ill m

odu

late

cap

acit

y t

o th

e H

ot s

etp

oin

t.

Syst

em C

onfi

gura

tion

Syst

em M

ode

Sele

ctio

n (B

AS

Mul

it-S

tate

Var

iabl

e)

Mod

e (4

)-A

uto

Full

Bui

ldin

g: T

he

syst

em w

ill o

per

ate

in M

ode

(5)-

Full

Bui

ldin

g. U

nit

s w

ill m

odu

late

cap

acit

y t

o th

e Se

con

dar

y lo

ad s

etp

oin

t.

Mod

e (6

)-P

rim

ary

Coo

ling:

T

he

syst

em w

ill o

per

ate

in M

ode

(2)-

Coo

ling

Onl

y. U

nit

s w

ill m

odu

late

cap

acit

y t

o th

e C

old

set

poi

nt.

NO

TE

2: H

eade

r R

ack

(2),

(3),

& (6

): N

on-A

pplic

able

(N

A) M

odes

sel

ecte

d w

ill o

pera

te a

s st

ated

bel

ow:

NO

TE

1: H

eade

r R

ack

(5) 6

-Pip

e D

edic

ated

Sou

rce:

Mod

e (4

) & M

ode

(5)

are

Non

-Ap

pli

cab

le. I

f Mod

e (4

) or

(5) i

s se

lect

ed t

he

un

it w

ill o

per

ate

in M

ode

(1) O

FF w

/Iso

Ope

n.

Hea

der

Rac

k C

onfi

gura

tion

Com

pre

ssor

s C

ircu

it T

yp

eC

ontr

ol-T

o T

emp

erat

ure

Op

erat

ing

Mod

es


73


Wiring Diagram

LON

DAT

ALO

N St

atus

MS/

TP TK

NM

S/TP

PKT + _

LONLON

PowerGNDGND

Babe

lBu

ster

2

NOTE

1

USB

PRI

SEC

RS-4

85-1

S

- +

S

- +

RS-4

85-2

A1A2

A3A4

A5A6

A7A8

CC

CC

U1

U2

U3

U4

U5

U6

U7

CC

CC

U8

U9

U12

U13

U14

U15

CC

CC

U16

U10

U11

D1

D4

D5

D6

D7

CC

CC

D8

D2

D3

D9

CD

1024

VAC/

DC~ -~

+

SHLD

LxHLxL

Hy

dr

oLin

k 2

niag

ara

534

JEN

E-EG

534

Fram

ewor

k

TxR

xTx

Rx

UN

IVER

SIAL

IN

PUTS

ANAL

OG

O

UTP

UTS

D1

D2

D3

D4

D5

D5

DIG

ITAL

OU

TPU

TS

Bras

s Scr

ews

Supe

rviso

ry C

ontro

l Pan

el No

tes

L N G

120V

ac F

ield S

uppl

yVo

ltage

PB1

1 21

CAT5

Cab

le

Silve

r Scr

ews

Gree

n/Ye

llow

(8)

TT

TT

TT

NET

ENER

GY

LOOP

HEA

DER

BYPA

SSVa

lve

HOT

LOOP

HE

ADER

BYPA

SSVa

lve

COLD

LOO

P HE

ADER

BY

PASS

Valve

3. Op

tiona

l field

wirin

g fo

r Bac

Net I

/P c

onne

ction

to B

AS.

2. RS

485

field

wire

d co

nnec

tion

shou

ld be

dais

y cha

ined t

o ch

iller b

ank.

Requ

ires 2

2 awg

sh

ielde

d tw

isted

pai

r cab

le.

0-10

Com

24V

0-10

Com

24V

0-10

Com

24V

2 31 PB2

6. 24

Vdc P

ower

supp

ly bo

ard

1(PS

B-1)

cann

ot po

wer a

nyth

ing ot

her t

han

the

Hydr

olink

2, Hy

droL

ink2

I/O m

odule

s and

HM

I.

UN

IVER

SIAL

IN

PUTS

TT

D6

D7

D8

D9

D10

POW

ER S

UPPL

Y BO

ARD

RC

23

41

34

52

1

P2P1

23

41

34

52

1

P4P3

GND

24V P5

+5V

+24Vdc

GND

USB

USB

5A

Facto

ry W

iring

Field

Wirin

g

Optio

nal B

lock

Grou

nd

Lege

nd

Outsi

de o

f Enc

losur

e

Powe

rbloc

kPB

2

Diffe

rentia

l Pres

sure

Tran

sduc

er

Dry C

onta

ct

T10

KOhm

Tem

p Se

nsor

0-10

Com

24V

Valve

Con

necti

on

F1Fu

se

1. Op

tiona

l Tem

pera

ture

sens

ors,

Pres

sure

tran

sduc

ers a

nd B

ypas

s val

ves l

ocat

ed o

n he

ader

rack

nee

d to

be

field

wire

d.

4. Op

tiona

l RS4

85 fie

ld wi

red co

nnec

tion t

o BAS

.

97P8

38-X

X8/

21/20

18

7. Fi

eld su

pplie

d an

d fie

ld wi

red

devic

e.

POW

ER S

UPPL

Y BO

ARD

RC

23

41

34

52

1

P2P1

23

41

34

52

1

P4P3

GND

24V P5

+5V

+24VDC

GND

USB

USB

5A

Powe

r Sup

ply

Boar

dPS

B-1

PSB-

1

PSB-

2

Resis

tor

8. Pr

essu

re tr

ansd

ucer

s req

uire

a 25

0Ω re

sisto

r be

wire

d as s

hown

.

5. Op

tiona

l field

wire

d Lon

Wor

ks co

nnec

tion t

o the

BAS

.

Transformer

Blac

k/W

hite

Transformer

Whi

te (7

)

Blac

k (6

)

Blac

k

Whi

te

Whi

te

Blac

k

Yello

w

Table

t

2 31 PB1

Blac

k/W

hite

Yello

w

Blac

k (1

0)

Yello

w (1

1)

Yello

w (+

24Va

c) Blac

k (2

4Vac

com

)

Red

(+24

Vdc)

Blac

k (2

4Vdc

com

)

Blac

k (2

4Vdc

com

)

Red

(+24

Vdc)

9VD

C Ad

apto

r

Wire

less

Rout

erPowe

r

Red

(+24

Vdc)

24VD

C Po

wer

Blo

ck

Blac

k (2

4Vdc

com

)

2 31PB3

Refr

iger

ant

Mon

itor

ing

A1

C

C

A2

A3

U1

CU

2U

3C

U4 U

5C

U6

U7

CU

8

9Vdc

Blac

k (2

4Vdc

com

)

Red

(+24

Vdc)

NOTE

5

Opt

iona

l Lon

Wor

ks

BAS

Conn

ectio

n

NOTE

1

Gree

n/Ye

llow

(9)

Mou

nting

Pla

teDo

or

24Va

c Pow

er B

lock

s

NOTE

2

NOTE

3

NOTE

4

NOTE

7

NOTE

8

9. Re

quire

s twi

sted

pair

shiel

ded 2

2awg

com

mun

icatio

n wi

re.

NOTE

9

NOTE

9

NOTE

9

V+

IOU

T V

OU

T C

OM

ZER

O V

+ IO

UT

VO

UT

CO

M Z

ERO

V+

IOU

T V

OU

T C

OM

ZE

RO

Hot L

oop

DP

Tran

sduc

erCo

ld L

oop

DP

Tran

sduc

erSo

urce

Loop

DP

Tra

nsdu

cer

V+

IO

UT

V

OU

T

CO

M

ZER

O

74


Port Layout

75


System Confi gurationThere are several different modes of operation depending on the type of system present. Below we discuss the different header rack confi guration and the system modes of operation.

Types of Header Racks1 = Header Rack Not Confi gured 2 = 4 Pipe Standard - (Non-Reversing Compressors)3 = 4 Pipe Reversing - (Non-Reversing Compressors)4 = 6 Pipe Standard - (Non-Reversing Compressors)5 = 6 Pipe Dedicated Source - (Reversing Compressors)6 = 4 Pipe Standard - (Reversing Compressors)7 = No Header Rack

Modes of operation for units with Header Racks 1 = Off with isolation valves open2 = Cooling Only 3 = Heating Only4 = Auto Full Building - (6-Pipe Only)5 = Full Building6 = Primary Cooling - (6-Pipe Only)7 = Primary Heating - (6-Pipe Only) 8 = Off with isolation valves closed

76


Revision GuidePages: Description: Date: By:

All Document Created 19 Oct 2017 MA

77


Notes

Product: HydroLink2 Aurora Supervisory Control

Document Type: Application and Troubleshooting GuidePart Number: AG1571EWRevision Date: 07/19

HydroLink2 Supervisory Control Panel - Application and ...chiller with the least amount of run time...

Documents

Transcript of HydroLink2 Supervisory Control Panel - Application and ...chiller with the least amount of run time...